Variable intensity spray dispenser



May '7, 1968 D. F. ARMOUR VARIABLE INTENSITY SPRAY DISPENSER 6 Sheets-Sheet 1 Filed Dec. 30, 1966 PM; I

INVENTOR. DONALD F. ARMOUR :giogdwwd Q3 NE Y D. F. ARMOUR May 7, 1968 VARIABLE INTENSITY SPRAY DISPENSER 6 Sheets-Sheet Filed Dec. 50, 1966 FIG; .22

INVENTOR. DONALD F. ARMOUR y 1968 D. F. ARMOUR 3,381,860

VARIABLE INTENSITY SPRAY DISPENSER Filed Dec. 30, 1966 6 Sheets-Sheet 3 g@ f x 1 0 "44 9 l X2 i 82 f 1} 0 4 f 1: m 1' A 7/ w/ 1% 48 4 M l 4? 4i 1 l 1k, g SQQ: N

INVENTOR.

DONALD F. ARMOUR mudf ogmu'uu ORNE Y:

y 7, 1958 D. F. ARMOUR 3,381,860

VARIABLE INTENSITY SPRAY DISPENSER Filed Dec. 30, 1966 6 Sheets-Sheet 4 INVENTOR.

DONALD F. ARMOUR M @Ef qma/w RNE Y:

May 7, 1968 D. F. ARMOUR 3,381,860

VARIABLE INTENSITY SPRAY DISPENSER Filed Dec. 50. 1966 6 Sheets-Sheet 5 INVENTOR. DONALD F. ARMOUR RNE Y:

y 1968 D. F. ARMOUR 3,381,860

VARIABLE INTENSITY SPRAY DISPENSER INVENTOR. DONALD F. ARMOUR ORNE Y-' Unite A dispenser for a flexible walled container, having a discharge orifice capable of emitting variable intensity sprays, by means of the cooperation between air restricting means associated with the container neck, and an opening in the rotary neck plug. On squeezing the container, air passes through the opening into a mixing chamber in the plug where it is mixed with liquid entering the chamber through another inlet, and then emitted as a spray through the discharge orifice. Spray intensity is varied by moving the plug to change the size of the air opening, as defined by the extent of its obstruction by the restricting means.

This application is a continuation-in-part of copending application Ser. No. 491,547, now abandoned, filed Sept. 30, 1965.

The present invention relates generally to a new and useful spray dispenser, and particularly to a spray dispenser capable of emitting varying intensity sprays.

There are in existence various types of spray containers constructed of a variety of materials which utilize intricate and involved mechanisms to produce a spray of a uniform texture and density. These spray containers generally fail to provide for the desired degree of flexibility needed in adjusting the intensity of a spray to suit a particular application. Available spray containers which do not allow flexibility generally do so only at the sacrifice of simplicity of construction, or at a cost which is prohibitive for most applications.

It is therefore an object of this invent-ion to provide a new and useful spray dispenser which provides advantages in terms of simplicity of construction and operation over spray dispensing devices presently available.

It is a particular object of this invention to provide an improved dispenser capable of delivering varying intensity sprays.

It is a further object of the present invention to provide an improved dispenser capable of delivering varying intensity sprays through a single outlet.

An additional object of this invention is to provide an interrelated dispenser plug assembly and cap with means for insuring accurate and positive positioning of the components of the device.

In specifically describing the present invention, wherein additional objects thereof will become more apparent, reference will be made to preferred embodiments illustrated in the accompanying drawings wherein:

FIG. I is an elevational view in perspective of the spray dispenser of the present invention, illustrating the improved dispenser outlet.

FIG. II is a fragmentary view of the spray dispenser of FIG. I with components shown in axially separated relationship, and axially sectioned through the central axis of the dispenser plug assembly and closure.

FIG. III is a fragmentary, elevational, axially sectioned view of the dispenser of FIG. II with parts in assembled States Patent "ice form, illustrating the setting allowing maximum air fiow through the dispenser.

FIG. IV is a view similar to FIG. III illustrating the setting allowing minimum air flow through the dispenser, in which the dispenser plug is rotating from that of FIG. III.

FIG. V is a horizontal sectional view along the line V-V of FIG. IV showing the upper end of the dispenser plug.

FIG. VI is a horizontal crosssectional view along the line VI-VI of FIG. III.

FIG. VII is a horizontal cross-sectional view along the line VIIVII of FIG. IV.

FIG. VIII is a fragmentary, axial-1y sectioned, elevational view of the dispenser plug assembly taken through its central axis.

FIG. IX is a view similar to FIG. II of an alternate embodiment of the present invention.

FIG. X is an elevational view of the dispenser plug of the alternate embodiment of FIG. IX.

The present invention has been achieved by development of a spray dispenser which includes a flexible walled liquid container, and a rotary plug assembly having a discharge orifice capable of emitting variable intensity sprays by means of the cooperation between air restricting means associated with the container neck, and an air passageway in the plug assembly mounted in the neck. Spray intensity is varied by rotation of the plug to change the size of the air opening as defined by the extent of its obstruction by the restricting means.

More specifically, in the preferred embodiment, the novel spray dispenser of the present invention comprises a container having an open ended hollow neck which has a shoulder projecting inwardly from the inner surface of the neck and extending around the periphery of the neck, a portion of the shoulder extending axially upward, a generally cylindrical end portion of the neck projecting axially upward from the inner edge of the shoulder, and a hollow plug assembly within the neck rotatably mounted on the cylindrical end portion of the neck, the plug assembly having an upper end with an orifice therein, a mixing chamber in the upper end beneath and open to the orifice, a tube having one end adjacent to and in axial alignment with the mixing chamber, and the other end within the container, a closed bot-tom surrounding the tube which projects therethrough, an air channel communicating with the mixing chamber and the interior of the plug assembly, a depending skirt having an aperture defining an opening between the interior of the plug assembly and the interior of the container, which cooperates with the inner surface of the shoulder as the plug assembly is rotated on the neck, causing the opening to gradually change in size.

As shown in FIG. I, a liquid container or bottle 10 is provided having a flexible side wall fabricated from a synthetic resinuous material. Container 10 has plug assembly 14 mounted thereon for spraying liquid from within the container. Referring to FIGS. H and VIII, plug assembly 14 comprises plug 16, tubular member 18 and sleeve 29. Though not critical to the present invention, plug 16, tubular member 18 and sleeve 20 may be preassembled to constitute plug assembly 14 prior to insertion into the bottle neck. Such preassembly aflords ease and economy in completion of the final package. More specifically, after bottle 10 is filled with a liquid to be dispensed, assembly costs are reduced, since all of the operative components of the plug assembly may have been separately preassembled and need then only be inserted in assembled form into the neck of the bottle without requiring preorientation.

Plug 16 comprises top wall 22 in which there is centrally located a discharge orifice 24. Top wall 22 has annular mixing chamber 26, below, adjacent to, and in axial alignment with orifice 24. Angular air channels 28a and 28b are further provided on the center line of the underside of top wall 22 as depicted in FIG. V, providing a passageway between the hollow interior 31 of plug 16 and mixing chamber 26. One of these channels is necessary, two are preferred, and obviously additional channels may be used. Annular shoulder extends radially outwardly from the circumference of mixing chamber 26 to form a socket 32 shown in FIG. II into which slidingly fits the upper end 34 of tubular member 18. The outer surface of upper end 34 of tubular member 18, therefore defines the interior wall of angular channels 28a and 28b. Annular skirt 36 depends from the periphery of top wall 22 and has concentric cylindrical walls, comprising inner depending member 38 and outer member 40, the outer depending member 40 being of a lesser height and greater diameter than inner depending member 38. Outer depending member 40 is joined to depending skirt 36 by horizontal wall 42 at its upper end, and has inwardly extending flange 44 at its lower end. Pointer 46 extends downwardly at one point from the bottom face of outer depending member 40. Inner depending member 38 is provided with a slot 48 extending upward from its lower periphery. Further, there is provided an annular detent 50 around the inner circumference of member 38 adjacent its lower end.

Four ribs 52 extend inwardly from the inner circumference of annular skirt 36 and are spaced apart from each other, for example at 90 intervals. Ribs 52 extend downward from the underside of top wall 22 and must be spaced on either side of channels 28a and 28b, so not to obstruct the access openings to the mixing chamber provided by these channels. The inner edges 54 of ribs 52 abut against and frictionally engage the outer surface of tubular member 18 to prevent its inadvertent withdrawal, and to provide lateral stability at the upper end of tubular member 18. Ribs 52, in cooperation with tubular member 18 when inserted in socket 32, also define a plurality of axially extending channels 55 within the upper end of hollow interior 31 of the plug 16. At least one axial channel 55 requiring two ribs should be provided, in conjunction with the need for only one angular channel 28. Four ribs providing two axial channels accessible to two angular channels are preferred, though obviously ribs in excess of four will also yield satisfactory results.

Tubular member 18 extends downwardly from within plug 16 to the bottom or to a point adjacent the bottom of liquid container 10, and serves as a delivery tube for conveying liquid from the container to mixing chamber 26.

Sleeve member 20 comprises closed top 57 having a hole 58 therein, and an outwardly extending annular bead 60, sidewall 62, and an annular shoulder 63 at the lower end of side wall 62.

Referring now to FIG. II, the liquid container or bottle 10, comprises a bottom wall and a top wall 13, joined together by flexible side wall 12 so as to define a liquid reservoir. Container ltl has an open ended hollow tubular neck generally indicated as 64 extending upwardly from top wall 13. External threads 66- are provided on the outer surface at the lower end of neck 64. Above threads 66, restricting means associated with the neck are provided which may comprise shoulder 68 which projects inwardly from the inner surface of neck 64 around the full circumference thereof, as shown in FIG. III. As an important feature of the preferred embodiment of the present invention, at least a portion of shoulder 68 gradually tapers upwardly along two segments of the circumference, to a generally horizontal apex section 70. The outer surface of the non-tapered portion of shoulder 68 is depicted in FIG. 11 as 72,

with the outer surfaces of the tapered segments shown as 74a and 74b, and the outer surface of the apex as 76. In FIG. III the inner surface of a tapered segment is depicted as 78, and the inner surface of apex 70 shown as 80. The cavity defined by the inner surface of the upwardly tapering segments of the shoulder and by the apex at the top thereof is shown in FIG. III and IV as 71. The restricting means of the present invention is preferably an inwardly projecting shoulder, but may take other forms. Generally cylindrical end portion 82 of neck 64 extends upwardly from the inner edge of shoulder 68 around the full circumference thereof, including the tapered and apex portions of the shoulder. The outer surface of cylindrical end portion 82 appears as 84 in FIG. II. Annular flange 86 protrudes outwardly from the upper end of cylindrical end portion 82. Outer surface 84 may be marked in any suitable manner to represent the relative intensity of spray delivered through orifice 24 of plug 16. These indicia for example may be set forth as numbers graduated lines, or any other suitable representative means.

Generally, the spray dispenser of the present invention may be further equipped with a cap 88, which is internally threaded at 90 for engagement with external threads 66, of neck 64, of bottle 10 when the components are in assembled relationship as shown, for example, in- FIG. III. Furthermore, cap 88 is equipped on the underside of its top 92 with downwardly extending annular sealing ring 94 which sealably surrounds orifice 24 of plug 16 when cap 88 is completely screwed down on the container, and thus provides a seal between the bottle interior and the atmosphere.

As stated above, plug 16, tubular member 18, and sleeve 20 may be assembled to provide plug assembly 14, which then may be inserted as a unit into the neck of the bottle as depicted in FIGS. III and IV. When plug assembly 14 is assembled, the upper end of tubular member 18 fits into socket 32 in the underside of top wall 22 of plug 16 beneath mixing chamber 26, and is frictionally held in place by the series of internally projecting spaced ribs 52. Sleeve member 20 is in frictional engagement with tubular member 18, intermediate its length at a point adjacent to and above the lower end of inner depending member 38. Sleeve 20 is firmly held in position by outwardly extending annular bead 60 which resides in peripheral detent 5d of inner depending member 38. Further, shoulder 63 of sleeve 20 is in continual abutting relationship with the lowermost face of the inner depending member 38 and hence restricts any upward movement of sleeve 20. When in place, sleeve 20 and tubular member 18 projecting therethrough close off the lower open end of plug 16. When sleeve 20 engages the lower end of plug 16 in this manner, a portion of slot 48 is closed off from the hollow interior of the plug, but another portion 49 is unobstructed by the sleeve, so as to define an opening or passageway communicating with the interior of the plug and the interior of the container.

When plug assembly 14 is inserted in neck 64, the upper surface of inwardly extending flange 44 resiliently and lockingly fits against the lower face of annular flange 86 of cylindrical end section 82 of neck 64 so as to restrict axial movement of the plug assembly, while permitting unlimited rotational movement. When assembled, the outer surface of the lower end of annular skirt 36 snugly and sealably fits against the inner surface of cylindrical section 82 of the container neck. Ease of insertion of the plug assembly into the neck is aided by the fact that the outer diameter of the inwardly flaring inner depending member 38 is less than the inner diameter of cylindrical end section 82.

As seen in FIG. III and IV the upper surface 57 of sleeve 20, tubular member 18, and the internal walls of the plug skirt define annular air chamber 90 within the hollow interior of plug 16.

Operation of the spray device of the present invention is both simple and efiicient, and may be illustrated by reference to FIGS. III and IV. Container 10., with plug assembly 14 in place in the neck, contains liquid to be dispensed in a fine to a heavy spray. In FIG. HI the plug assembly is shown oriented in the container neck so as to dispense a fine spray on removing the cap, i.e. with a maximum amount of air. Opening 49, of slot 48, or" inner depending member 38, as shown, is aligned opposite apex section 70 of shoulder 68. As can be seen, the cross-sectional area in radial alignment with, and in front of, opening 49, is at a maximum with the plug in this position. Thus, depression of flexible wall 12 of container it forces liquid upward through tubular member 18 into mixing chamber 26. Simultaneously therewith, air from above the liquid level in the container flows through cavity 71, defined by the tapering and apex portions of shoulder 63, then through opening 49 into the hollow interior of plug 9, through annular air chamber 90 with n the hollow interior of plug 9, through the two channels 55 which are open to angular air channels 23a and 28b, over the upper end of tubular member 18 and into mixing chamber 26. In mixing chamber 26, the air and liquid are mixed to form a spray which then exists the dispenser via orifice 24. Upon release of pressure, the walls of the container return to their normal position, and air is admitted into the container through orifice 24, mixing chamber 26, downwardly through channels 55', chamber 99, opening 49, cavity 71 and into container it Repeated depression of the flexible walls of the container will then produce further spray as before described.

Plug assembly 14 rotates as a single unit. Therefore, when plug 16 is rotated in either direction, opening 49 moves away from alignment with the maximum crosssectional area provided by that portion of cavity 71 defined by the inner surface Stt of apex 70 and is aligned opposite a lesser open crosssectional area, because of the obstruction to the opening provided by the tapering portions of shoulder 68. Because of this lesser cross-sectional area, a smaller quantity of air enters through opening 49, and the intensity of the spray is thereby increased. Therefore, indicia appearing on either side of the apex on the outer surface of generally cylindrical end portion 82, of neck 64, indicates the relative intensity of spray. When opening 49 is aligned adjacent to apex "7 3 there is a ratio of up to three parts air to one part liquid. Thus, depending on the position of the plug assembly, this ratio may be varied at will to a point Where a minimum amount of air passes through the dispenser, whereby a ratio of up to three parts liquid to one part air is attained. This setting is illustrated in FIG. IV wherein opening 49 is shown rotated 180 from that depicted in FIG. III. The quantity of air which may pass through opening 49 with the plug assembly in this position, is confined to that which may initially pass through slit 88, defined by the inside surface of the lower end of cylindrical end portion 82 and the outside surface of inner depending member 38, or in the case of that portion of inner depending member 28 which is cut away as slot 48, the outer surface of side wall 62 of sleeve 20. As can be seen this minimum air ratio is not confined solely to the position depicted in FIG. IV, but exists at any point around the circumference where the tapering or apex portions of shoulder 68 do not exist.

As an alternate embodiment of the present invention, depicted in FiGS. IX and X, the taper is provided on the plug skirt rather than on the upwardly extending portion of the neck shoulder, which in this embodiment extends axially upward rather than tapers upwardly. More specifically, the inner cavity corresponding to 71 in the prior embodiment is essentially of a rectangular crosssection in this embodiment, as illustrated by outer surface 92 in F G. IX of the upwardly extending portion of the shoulder. In FIGS. IX and X, the opening in inner depending member 9 3- above sleeve 2t) is tapered, and is provided by terminating inner depending member 94 at one side 96 above sleeve 20, whereas the opposite side extends further downward and abuts shoulder 63 of sleeve 20, in the manner previously described. Annular detent 98 is provided in the downwardly extending section, as previously, to mate with bead 60 of sleeve 26. The inner depending member 94 is provided at one side thereof With a discontinuity 96 of varying height from side to side in the bottom thereof. By utilization of this embodiment, a maximum amount of air passes through the rectangular cavity when the discontinuity 96 is centrally aligned therewith. Any rotation of the plug assembly thereafter in either direction, varying height of the discontinuity 96 will constrict the opening proportionately with the amount of rotation. When using this modification of the present invention, the components are molded to afford the same ratios as in the preferred embodiment of the invention, i.e. a ratio of up to three parts air to one part liquid for a fine spray and up to three parts liquid to one part air for a wet spray.

It is important in the present invention that slit 83 provided by the inward flaring of the inner depending member of the plug be in existence, and that the plug skirt not abut against the inner surface of the cylindrical end portion, since if this were to occur, no air could reach the mixing chamber and pure liquid would be dispersed when the air opening or passageway was moved out of alignment With the upwardly projecting and apex portions of the shoulder.

The air velocity through the plug assembly is an important factor in determining spray intensity. The total open cross-sectional area of the angular channel through which air finally enters the mixing chamber must be less than the size of opening 49 of slot 48 in inner depending member 38. This is necessary to insure that a velocity is maintained through the axial channels which communicate with the angular channels to provide proper regulation of the spray air flow.

For a fine spray, obtained when the plug assembly is oriented, for example, in the position shown in FIG. III, it is preferred to keep the velocity high through cavity 71, and pass a maximum amount of air over the top end of liquid delivering tube 18 into the mixing chamber. On the other hand, when opening 49 is oriented so it is in alignment with slit 38, so as to produce a wet spray with minimum air flow, it is desired to minimize the effect of the air velocity and this is achieved with the larger cross section provided by annular expansion channel 9% in the bottom of the plug assembly. In this position the velocity of the air entering the mixing chamber is reduced to reduce atomizing intensity, and expel a wet spray with minimum air flow.

As stated above, the spray dispenser of the present invention represents an advance in the art because of its unique, hi hly controllable spray, and its simplicity and efficiency. The highly controllable spray intensity provided by the present invention has been heretofore unknown in the art. The simplicity and efiiciency features are best illustrated by the simplicity of mold designs for production of the components, and by the fact that preorientation of the parts is unnecessary when assembling the dispenser. in fact, no orientation is needed or required until the consumer rotates the plug to attain the spray suitable for his own personal requirements.

While the present invention has been described in detail, it is apparent that numerous modifications may be made without departing from the spirit and scope of the invention as set forth in the appended claims.

What is claimed is:

1. A spray dispenser comprising:

(a) acontainer having a hollow, open ended neck having a shoulder projecting inwardly from the inner surface of the neck and extending around the periphery of the neck, a portion of the shoulder extending axially upward, a generally cylindrical end portion of the neck projecting axially upward from the inner end of the shoulder; and (b) a hollow plug assembly within the neck rotatably mounted on the cylindrical end portion of the neck, the plug assembly having a generally closed bottom portion, an upper end with an orifice therein, and a mixing chamber in the upper end beneath and open to the orifice, liquid conveying means having one end adjacent to and in axial alignment with the mixing chamber, and the other end within receipt of liquid from the container, an air channel communicating with the mixing chamber and the interior of the plug assembly, a depending skirt having an aperture defining an opening between the interior of the plug assembly and the interior of the container, which cooperates with the inner surface of the shoulder as the plug assembly is rotated on the neck, causing the openin to gradually change in size. 2. A spray dispenser comprising: (a) a flexible walled container having a hollow, open ended neck having a shoulder projecting inwardly from the inner surface of the neck and extending around the periphery of the neck, a portion of the shoulder extending axially upward, a generally cylindrical end portion of the neck projecting axially upward from the inner end of the shoulder; and (b) a hollow plug assembly within the neck rotatably mounted on the cylindrical end portion of the neck, the plug assembly having an upper end with an orifice therein, and a mixing chamber in the upper end beneath and open to the orifice,

a tube having one end adjacent to and in axial alignment with the mixing chamber, and the other end within the container,

a closed bottom surrounding the tube which projects therethrough,

an air channel communicating with the mixing chamber and the interior of the plug assembly,

a depending skirt having an aperture defining an opening between the interior of the plug assembly and the interior of the container, which cooperates with the inner surface of the shoulder as the plug assembly is rotated on the neck, causing the opening to gradually change in size.

3. The dispenser of claim 2 wherein the depending skirt is radially spaced inward from the inner edge of the shoulder, and the closed bottom sealably surrounds the tube.

4. The dispenser of claim 2 wherein the upwardly extending portion of the shoulder gradually tapers to an apex.

5. The dispenser of claim 2 including a cap for the neck of the container, having sealing means designed to sealably surround the orifice of the plug assembly when the closure is engaged on the neck.

6. The dispenser of claim 2 wherein:

(a) the upper end of the hollow plug assembly is a generally horizontal top wall;

(b) a plurality of webs project inward from the inner surface of the plug assembly and frictionally engage the outer surface of the tube, at least two of said webs defining an axial channel which communicates with said air channel;

(c) the plug assembly has an annular lip on its outer surface; and

(d) the cylindrical end portion of the neck has an annular flange on its upper rim for engaging the annular lip of the plug assembly to prevent axial movement of the plug.

7. The dispenser of claim 2 including:

(a) locking means on the lower end of the depending skirt; and wherein (b) the closed bottom of the plug assembly comprises an annular sleeve for the skirt having a closed top with an opening through which the tube telescopes, the size of the opening being such that the outside surface of the tube sealably contacts the walls of the opening, the sleeve having cooperating locking means for engaging the locking means of the skirt.

8. The dispenser of claim 2 wherein:

(a) the upwardly extending portion of the shoulder projects upward substantially perpendicular to the remainder of the shoulder; and

(b) the depending skirt is annular and the aperture is formed by a discontinuity at the bottom of one side thereof, said discontinuity being of varying height from side to side.

9. The dispenser of claim 4, wherein the apex has a generally rectangular cross section.

10. The dispenser of claim 7 wherein:

(a) the locking means on the skirt is an annular groove on its interior surface near its lower end, and the cooperating locking means of the sleeve is an annular outwardly projecting bead;

(b) the sleeve has a step projecting outwardly from its lower end for engaging the bottom face of the skirt; and

(c) the aperture is a slot in the lower end of the skirt, a portion of which remains open when the sleeve matingly engages the skirt.

References Cited UNITED STATES PATENTS 2,764,453 9/1956 Robb et a1 222-648 2,924,393 2/1960 Robert 239-327 2,961,169 11/1960 Nyden 222211 X 3,118,578 1/1964 Collins 2222l2 X 3,170,633 2/1965 Castelli 239-327 ROBERT B. REEVES, Primary Examiner.

F. R. HANDREN, Assistant Examiner. 

